Active cover plates

ABSTRACT

Various embodiments of active cover plates are disclosed. Active cover plates may include a face plate, an electrical load, at least one clip extending rearward from the faceplate. The clip may include a contact, a resilient strip supporting the contact, wherein the contact is joined to the resilient strip and passes through the resilient strip, and a rear insulator covering a rear side of the contact. An electrical connection may be formed between the clip and the electrical load.

RELATED APPLICATIONS

The present application is a continuation-in-part, and claims thebenefit under 35 U.S.C. §120, of U.S. patent application Ser. No.15/428,099, filed Feb. 8, 2017, titled “Control Switch,” which is acontinuation-in-part of U.S. patent application Ser. No. 15/409,508,filed Jan. 18, 2017, titled “Current Limited Circuits” which claimspriority under 35 U.S.C. §119(e) to U.S. Provisional Application No.62/279,831, titled “Active Cover Plates”, filed Jan. 18, 2016. Theseapplications are hereby incorporated by reference in their entireties.

The present application is a continuation-in-part, and claims thebenefit under 35 U.S.C. §120, of U.S. patent application Ser. No.15/406,404, filed Jan. 13, 2017, titled “Active Cover Plates”, which isa continuation-in-part, and claims benefit under 35 U.S.C. §120, of U.S.patent application Ser. No. 15/145,749, filed May 3, 2016, titled“Active Cover Plates,” which is a continuation-in-part of and claims thebenefit under 35 U.S.C. §120, of U.S. application Ser. No. 14/549,143,titled “Active Cover Plates”, issued as U.S. Pat. No. 9,362,728, filedNov. 20, 2014, which is a continuation-in-part of U.S. patentapplication Ser. No. 14/066,621, issued as U.S. Pat. No. 9,035,180,filed Oct. 29, 2013, titled “Active Cover Plates,” which is acontinuation-in-part, and claims the benefit under 35 U.S.C. §120, ofU.S. application Ser. No. 13/461,915, titled “Active Cover Plates”,issued as U.S. Pat. No. 8,912,442, filed May 2, 2012, which claims thebenefit under 35 U.S.C. §119(e) of U.S. Provisional Application No.61/574,344, titled “Illuminated Cover Plate with Finger-like Contactorsfor Outlets and Light Switches”, filed Aug. 1, 2011. These applicationsare hereby incorporated by reference in their entireties.

U.S. patent application Ser. No. 15/145,749 further claims priorityunder 35 U.S.C. §119(e) to U.S. Provisional Application No. 62/279,831,titled “Active Cover Plates”, filed Jan. 18, 2016. These applicationsare hereby incorporated by reference in their entireties.

U.S. patent application Ser. No. 14/066,621 further claims priorityunder 35 U.S.C. §119(e) to U.S. Provisional Application No. 61/720,131,filed Oct. 30, 2012, titled “Active Cover Plates”; U.S. ProvisionalApplication 61/778,386, filed Mar. 12, 2013, titled “Modified Outletsfor Use with Active Cover Plates”; and U.S. Provisional Application61/836,972, filed Jun. 19, 2013, titled “Modified Electrical Devices”,which applications are incorporated by reference in their entireties.

U.S. patent application Ser. No. 14/549,143 further claims priorityunder 35 U.S.C. §119(e) to U.S. Provisional Application No. 61/906,651,filed Nov. 20, 2013, titled “Powered Wall Plates with Multi-functions”;U.S. Provisional Application No. 62/027,784, filed Jul. 23, 2014, titled“Active Cover Plates”; and U.S. Provisional Application No. 62/081,539,filed Nov. 18, 2014, titled “Active Cover Plates.” These applicationsare hereby incorporated by reference in their entireties.

The present application is also a continuation-in-part, and claims thebenefit under 35 U.S.C. §120, of U.S. patent application Ser. No.14/678,746, filed Apr. 3, 2015, titled “Modified Electrical Devices”,which is a continuation-in-part, and claims benefit under 35 U.S.C.§120, of U.S. patent application Ser. No. 14/066,637, issued as U.S.Pat. No. 9,035,181, filed Oct. 29, 2013, titled “Modified ElectricalDevices”, which is a continuation-in-part, and claims the benefit under35 U.S.C. §120, of U.S. application Ser. No. 13/461,915, titled “ActiveCover Plates”, issued as U.S. Pat. No. 8,912,442, filed May 2, 2012,which claims the benefit under 35 U.S.C. §119(e) of U.S. ProvisionalApplication No. 61/574,344, titled “Illuminated Cover Plate withFinger-like Contactors for Outlets and Light Switches”, filed Aug. 1,2011. These applications are hereby incorporated by reference in theirentireties.

U.S. patent application Ser. No. 14/066,637 further claims priorityunder 35 U.S.C. §119(e) to U.S. Provisional Application No. 61/720,131,filed Oct. 30, 2012, titled “Active Cover Plates”; U.S. ProvisionalApplication 61/778,386, filed Mar. 12, 2013, titled “Modified Outletsfor Use with Active Cover Plates”; and U.S. Provisional Application61/836,972, filed Jun. 19, 2013, titled “Modified Electrical Devices”,which applications are incorporated by reference in their entireties.

BACKGROUND

Modern buildings include wiring to deliver electrical power to lights,outlets, and other devices. The electrical wiring terminates in anelectrical box in a wall, ceiling, floor or connected to anotherstructural element. Connections are made to the wiring in the electricalbox. For example, electrical wiring may be connected to outlet bodies bystab-in connectors or with screw terminals on the sides of the outletbody. After installation, a cover plate is placed over the outlet bodyto cover the opening to the box while allowing access to the outletreceptacles on the face of the outlet body. Similar connections are madewhen installing switches, which are also covered with a cover plate.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate various examples of the principlesdescribed herein and are a part of the specification. The illustratedexamples are merely examples and do not limit the scope of the claims.

FIGS. 1A, 1B, and 1C show an outlet and an illustrative active coverplate that is configured to fit over the outlet, according to oneexample of principles described herein.

FIGS. 2A, 2B, and 2C show views of an illustrative active cover platethat is configured to be used over an outlet receptacle, according toone example of principles described herein.

FIG. 3 shows the active cover plate of FIGS. 2A-2C placed over anoutlet, according to one example of principles described herein.

FIGS. 4A, 4B, and 4C show various illustrative embodiments of springclips extending rearward from a face plate of an active cover plate,according to one example of principles described herein.

FIGS. 5A, 5B, and 5C show a front view of a single pole light switch, arear view of an active cover plate configured to be used over a singlepole light switch, and a rear view of an active cover plate configuredto be used on a multipole light switch, according to one example ofprinciples described herein.

FIGS. 6A and 6B show various views of one embodiment of an active coverplate for use with an electrical receptacle, according to one example ofprinciples described herein.

FIGS. 7A and 7B show rear views of an illustrative active cover platefor use with an electrical receptacle, according to one example ofprinciples described herein.

FIG. 8 shows a perspective view of an illustrative spring clip mountedto the back of a face plate, according to one example of principlesdescribed herein.

FIGS. 9A and 9B show rear views of an illustrative active cover platefor use with an electrical receptacle, according to one example ofprinciples described herein.

FIG. 10 shows a perspective view of an illustrative spring clip mountedto the back of a face plate, according to one example of principlesdescribed herein.

FIG. 11 shows a partially cutaway bottom view of an illustrative activecover plate mounted over an outlet receptacle mounted in a receptaclebox, according to one example of principles described herein.

FIG. 12 is a perspective view of an active cover plate, according to oneexample of principles described herein.

FIG. 13 is a perspective view of an illustrative spring clip mounted tothe rear face of a face plate, according to one example of principlesdescribed herein.

FIGS. 14A and 14B are a side view and a perspective rear view of aspring clip/prong, according to one example of principles describedherein.

FIG. 15 shows a conductor and insulator for a spring clip, according toone example of principles described herein.

FIGS. 16A and 16B are a perspective view and top view of a spring clip,respectively, according to one example of principles described herein.

Throughout the drawings, identical reference numbers designate similar,but not necessarily identical, elements.

DETAILED DESCRIPTION

Reference will now be made to the figures wherein like structures willbe provided with like reference designations. In the followingdescription, for purposes of explanation, numerous specific details areset forth in order to provide a thorough understanding of the presentsystems and methods. It will be apparent, however, that systems andmethods may be practiced without these specific details. It isunderstood that the figures are diagrammatic and schematicrepresentations of some embodiments of the invention, and are notlimiting of the present invention, nor are they necessarily drawn toscale. Reference in the specification to “an example” or similarlanguage means that a particular feature, structure, or characteristicdescribed in connection with the example is included in at least thatone example, but not necessarily in other examples.

Additionally, features shown and/or described in connection with onefigure may be combined with features shown and/or described inconnection with other figures. As used in the present specification andin the appended claims, the term “a number of” or similar language ismeant to be understood broadly as any positive number comprising 1 toinfinity; zero not being a number, but the absence of a number.

FIGS. 1A, 1B and 1C illustrate an outlet body (100) and connection of anactive cover plate (150) to the outlet body (100). In this example, theoutlet body (100) is a duplex style National Electrical ManufacturersAssociation (NEMA) outlet body. The outlet body (100) includes twooutlet receptacles (115). Each outlet receptacle (115) includes twopower slots (120) and a ground (125).

On either side of the outlet body (100) are screw terminals (105, 110).The building wiring may be connected to the screw terminals by wrappinga stripped end of the house wiring around the screw and then tighteningthe screw to sandwich the wire between the bottom of the screw and aconductive plate. There may be a first screw terminal on a first side ofthe outlet body that is connected to a neutral building wire and asecond screw terminal on the same or an opposite side of the outlet bodythat is connected to a hot building wire. For example, the left terminal(105) may be connected to the neutral building wire and the rightterminal (110) may be connected to the hot building wire. The screwterminals make internal connections to contacts in the outlet body(100). When an electrical cord is plugged into the outlet receptacle(115), the blades of the electrical cord enter the power slots (120) andmake an electrical connection with the contacts. This allows currentfrom the building wiring to pass through the outlet body (100) and intothe cord. The outlet body (100) also includes two brackets/yokes (135)to connect it to an electrical box.

FIG. 1B shows a side view of the outlet body (100) showing one of thescrew terminals (110). The screw terminal (110) in this example includesconductive backing plates (140, 142) and two screws (112, 114) thatthread into the backing plates (140, 142). The backing plates (140, 142)are electrically and mechanically joined by a break off tab (145). Thebreak off tab (145) can be removed to electrically isolate the firstscrew (112) and its backing plate (142) from the second screw (114) andits backing plate (140).

FIG. 1C shows an active cover plate (150) that is mounted over theoutlet body (100). The active cover plate (150) includes a face plate(155) and two spring clips (160) extending rearward from the face plate.In this view, only one spring clip is visible, the other spring clipbeing directly opposite the first spring clip (see FIG. 12 for aperspective view showing an illustrative embodiment with two springclips). Each spring clip (160) includes an electrical contact (165).When the active cover plate (150) is placed over the outlet (100), thetwo spring clips (160) bring the electrical contacts (165) into contactwith the screw terminals (105, 110) on either side of the outlet body(100). Ordinarily, the electrical contacts (165) make contact with theheads of the screws (112, 114) because the heads of the screws (112,114) extend away from the outlet body (100) the farthest. The screwterminals (105, 110) are connected to the building wiring (170, 175).This allows the active cover plate (150) to extract electrical powerfrom the outlet body (100) through the spring clips (160).

Spring clips that extract electrical power from an outlet body or otherreceptacle body to power an active cover plate may have a number ofadvantages, including reliability and simplicity. However, the screwterminals may have a variety of positions on the side of the outletbodies. The location of the screw terminals varies according to the typeof outlet body and the manufacturer. While dimensions on the face of theoutlet body are generally consistent, the variance in the location ofthe screw terminals on the sides of the outlet body can produce asignificant challenge in creating an active cover plate that fits mostor all of the outlets present on the market and/or installed inbuildings.

An outlet body is only one example of an electrical device that anactive cover plate could interface with. Other examples include switchbodies and electrical boxes with connections for lights, fire alarms,CATS cable connections, phone jacks, or other installations over or inelectrical boxes. In general, the body that a cover plate of any typefits over is referred to as the “receptacle body.”

FIGS. 2A, 2B, and 2C show views of an illustrative active cover plate(200) that is configured to be used over an outlet receptacle. FIG. 2Aillustrates a front view of the cover plate (200); FIG. 2B illustrates arear perspective view of the cover plate (200); and FIG. 2C illustratesa top view of the cover plate (200). In at least one implementation, thecover plate (200) is configured to be placed over an outlet (i.e., thecover plate (200) prevents access to an electrical box containing anoutlet unless removed).

FIGS. 2A, 2B and 2C show that a cover plate (200) can include a faceplate (202). In at least one implementation, the face plate (202) canmate with the outlet to prevent access to the electrical box in whichthe outlet is mounted. For example, the face plate (202) can, incombination with the outlet, prevent access to the wires and connectionswithin the electrical box. The face plate (202) can include aninsulating material to prevent electrocution of a user. For example, theface plate (202) can include plastic. The face plate (202) can be asingle color or can include designs as desired.

FIGS. 2A, 2B and 2C also show that the cover plate (200) can include oneor more apertures (204). In at least one implementation, the one or moreapertures (204) can provide access to the outlet (i.e., the cover plate(200) covers a portion of an outlet but allows access to anotherportion). For example, the face plate (202) can prevent access toelectrical connections or wiring, while the one or more apertures (204)can allow access to the actual outlet.

FIGS. 2A, 2B and 2C further show that the cover plate (200) can includean attachment (206). In at least one implementation, the attachment(206) can include a screw hole or attached screw. The screw is theninserted into a bore in the outlet which holds the cover plate (200) inplace relative to the outlet. Additionally or alternatively, theattachment (206) can include one or more tabs that attach to the outletor electrical box. For example, the tabs may be inserted into a hole inthe outlet or electrical box and be retained by a flange or othermechanism within the outlet or electrical box.

FIGS. 2A, 2B and 2C additionally show that the cover plate (200) caninclude a first conducting strip (208 a) and a second conducting strip(208 b) (collectively “conducting strips (208)”). In at least oneimplementation, the conducting strips (208) can allow the cover plate todraw power (i.e., the conducting strips (208) come in contact with thepower connectors/screw terminals of the outlet, drawing power as needed,as described below).

One of skill in the art will appreciate that the conducting strips (208)can be connected to a power supply in some other way. In particular, theconducting strips (208) can be powered wirelessly. For example, theelectrical box can include a hardwired inductance mechanism. Theconducting strips (208) can be attached to another inductance mechanism,which allows power transfer without a physical connection.

FIGS. 2A, 2B and 2C also show that the cover plate (200) can include afirst insulating tab (210 a) and a second insulating tab (210 b)(collectively “insulating tabs (210)”). In at least one implementation,the insulating tabs (210) can prevent the conducting strips (208) fromforming a circuit with external materials (i.e. as the conducting strips(208) come in contact with the power connectors/screw terminals of theoutlet, they bend outward and could contact the side of the electricalbox or other external materials). This flexibility ensures that theconducting strips (208) remain in contact with the powerconnectors/screw terminals. However, it can also force the conductingstrips (208) toward wires, the electrical box or other materials in thearea. The insulating tabs (210) prevent the conducting strips (208) fromcontacting the wires, electrical box or other materials. In addition,the insulating tabs (210) prevent arcing if the conducting strips (208)get too close to the wires, electrical box or other materials.

The insulating tabs (210) can be the same material as the face plate(202) or can be attached to the face plate (202). For example, the faceplate (202) and the insulating tabs (210) can be constructed of a singlepiece of insulating material. Additionally or alternatively, theinsulating tabs (210) can be manufactured separately and then attachedto the face plate (202). One of skill in the art will appreciate thatthe attachment method should retain the insulating capabilities of theinsulating tabs (210). For example, the insulating tabs (210) can beattached to the face plate (202) using an insulating glue.

FIGS. 2A, 2B and 2C further show that the cover plate (200) can includea load (212). In at least one implementation, the load (212) can includeany electrical device which requires power. For example, the load (212)can include an electrical device embedded within the cover plate (200).Specifically, the load (212) can include lights, motion detectors,photocells, wireless nodes, Bluetooth connectors, smoke detectors,carbon monoxide detectors, cameras, heat detectors, speakers,microphones or any other desired electrical device.

FIGS. 2A, 2B and 2C exemplarily show a load (212) which includes a bankof light emitting diodes. A light-emitting diode (LED) is asemiconductor light source. LEDs can produce high intensity light withless power than conventional light sources. In particular, LEDs converta higher percentage of input power to light and a lower percentage toheat or other waste. In this example there are three LEDs mounted alongthe lower edge of the cover plate (200). The LEDs can be configured toemit light out of apertures along the lower edge of the cover plate(200).

FIGS. 2A, 2B and 2C additionally show that the cover plate (200) caninclude a power switch (214). In at least one implementation, the powerswitch (214) can allow a user to turn on or off or dim the load (212).For example, if the load (212) is a light, the power switch (214) canallow the user to select the brightness of the light or to turn off thelight such that it does not produce light.

FIGS. 2A, 2B and 2C also show that the cover plate (200) can include abattery backup (216). In at least one implementation, the battery backup(216) can ensure that the load (212) continues to receive power for atime, even if power from the power source is discontinued (i.e., thebattery backup (216) can be charged by the power source when the powersource is active). When the power source is inactive, the battery backup(216) can supply power to the load (212). The battery backup (216) canbe configured to provide power to the load (212) but not to the powersource, so that when the power source is inactive it does not act as anadditional load on the battery backup (216).

FIGS. 2A, 2B and 2C further show that the cover plate (200) can includea network device (218). In at least one implementation, the networkdevice (218) can allow the cover plate (200) to connect to a network.For example, the network device (218) can include an antenna.Additionally or alternatively, the network device (218) can include anEthernet port or any other connection capable of connecting the coverplate (200) to a desired network.

In at least one implementation, the network can be used to connectmultiple cover plates (200) to one another. Additionally oralternatively, the network can allow the cover plate (200) tocommunicate with a controller or over the Web. The network exemplarilyincludes the Internet, including a global internetwork formed by logicaland physical connections between multiple wide area networks and/orlocal area networks and can optionally include the World Wide Web(“Web”), including a system of interlinked hypertext documents accessedvia the Internet. Alternately or additionally, the network includes oneor more cellular RF networks and/or one or more wired and/or wirelessnetworks such as, but not limited to, 802.xx networks, Bluetooth accesspoints, wireless access points, IP-based networks, or the like. Forexample, the network can include cloud based networking and computing.The network can also include servers that enable one type of network tointerface with another type of network.

FIG. 3 illustrates a rear view of the cover plate (200) in combinationwith the outlet (100). In at least one implementation, the cover plate(200) is configured to be installed on the outlet (100) without the needfor hardwiring the cover plate (200). In addition, the cover plate (200)can electrically connect to the outlet/electrical receptacle (100)without occupying a socket in the outlet/electrical receptacle (100).

FIG. 3 shows that the first conducting strip (208 a) is in contact withthe first power screw (114). In at least one implementation, the firstconducting strip (208 a) receives power supplied to the first powerscrew (114). The power can then be delivered to a load (212) within thecover plate (200). One of skill in the art will appreciate that thefirst conducting strip (208 a) making contact with the first power screw(114) is exemplary only. For example, the first conducting strip (208 a)can make contact with another power screw (112, 116, 118), theconnecting tab between screws (e.g. 145, FIG. 1B), or can receive powerin some other way.

FIG. 3 also shows that the second conducting strip (208 b) is in contactwith the first neutral screw (118). In at least one implementation, thesecond conducting strip (208 b) completes the circuit with a firstneutral screw (118). For example, power may be received in the firstconducting strip (208 a) from the first power screw (114), delivered tothe load (212), then returned to the first neutral screw (118) using thesecond conducting strip (208 b). One of skill in the art will appreciatethat the second conducting strip (208 b) making contact with the firstneutral screw (118) is exemplary only. For example, the secondconducting strip (208 b) can make contact with the second neutral screw(116), the connecting tab between screws (e.g. 145, FIG. 1B), or cancomplete the circuit in some other way.

FIG. 3 further shows that the load (212) can be active at least whenpower is being supplied to the first power screw (114) (i.e., as long asa socket receiving power from the first power screw (114) could be usedas a power supply for a plug, the load (212) is receiving power). One ofskill in the art will appreciate that if the socket is controlled by aswitch then the load (212) will likewise be controlled by the switch.

FIG. 3 additionally shows that the battery backup (216) can complete acircuit with the first conducting strip (208 a) and the secondconducting strip (208 b). That is, as long as a socket receiving powerfrom the first power screw (114) could be used as a power supply for aplug, the battery backup (216) is receiving power. Thus, if power isdiscontinued to the power screw (114), the battery backup (216) is nolonger receiving power. However, the battery backup (216) can continueto supply power to the load (212), allowing it to remain active for atime.

Thus, in one example, a cover plate (200) for an outlet/electricalreceptacle (100) includes a first conducting strip (208 a), wherein thefirst conducting strip (208 a) protrudes rearward from the cover plate(200). The first conducting strip (208 a) is configured to contact afirst screw terminal (e.g. 110, FIGS. 1A, 1B) of an outlet/electricalreceptacle. The first screw terminal of the outlet/electrical receptacle(100) connects the outlet/electrical receptacle (100) to a power source.The cover plate (200) may also include a first insulator (210 a, FIG.2C) to prevent the first conducting strip (208 a) from contactingconducting materials other than the first screw terminal (e.g. 110,FIGS. 1A, 1B).

The cover plate (200) may also include a second conducting strip (208 b)which also protrudes rearward from the cover plate (200). The secondconducting strip (208 b) is configured to contact a second screwterminal (e.g. 105, FIGS. 1A, 1B; 116, 118, FIG. 3) of anoutlet/electrical receptacle (100). The second screw terminals (116,118) of the outlet/electrical receptacle (100) also connect theoutlet/electrical receptacle (100) to a power source. The cover plate(200) may also include a second insulator (210 b, FIG. 2C) to preventthe second conducting strip (208 b) from contacting conducting materialsother than the second screw terminals (116, 118).

FIGS. 4A, 4B, and 4C show various illustrative embodiments of springclips extending rearward from a face plate of an active cover plate.

FIG. 4A shows an illustrative cross sectional diagram of a powerextractor (401) that is fastened to the face plate (405) of an activecover plate. In this example, the power extractor (401) includes aresilient conductor (410), flexible insulation (425) and separateinsulating tab (415). The resilient conductor (410) and the separateinsulating tab (415) extend rearward from the face plate (405). Asdiscussed and shown above, this resilient conductor (410) is configuredto make electrical contact with a power terminal/screw terminal of anoutlet/electrical receptacle. In this implementation, portions of theresilient conductor (410) that will not make electrical contact with thepower terminal/screw terminal are coated with conformal insulation(425). An exposed portion (420) of the resilient conductor (410) makescontact with an electrified portion of the outlet/electrical receptacle.In this embodiment, a separate insulating tab (415) is positionedbetween the rearward extending portion of the resilient conductor (410)and the edge of the face plate (405). The insulating tab (415) extendsout from the face plate (405) farther than the resilient conductor(410). This can prevent contact between the resilient conductor (410)and surrounding materials in a variety of ways. For example, theinsulating tab (415) may be interposed between the surrounding materialsand the resilient conductor (410) when the active cover plate is inplace. In some examples, the insulating tab (415) may push surroundingmaterials away from the resilient conductors (410) when the active coverplate is mounted over the outlet/electrical receptacle. As discussed inmore detail below, the insulating tab (415) may also be useful inguiding the active cover plate (400) so that it will correctly alignover the outlet/electrical receptacle. For example, the insulating tab(415) may assist in correctly placing the active cover plate over theoutlet/electrical receptacle by sliding over the outlet/electricalreceptacle and guiding the active cover plate so that the exposedportion (420) of the resilient conductors (410) contact the desiredelectrified portion of the outlet/electrical receptacle. The insulatingtab (415) may also interact with the electrical box that houses theoutlet/electrical receptacle to provide positioning guidance. In theexample shown in FIG. 4A, the insulating tab (415) is angled at the topto guide the outlet/electrical receptacle into a central positionbetween two opposing resilient conductors (410).

FIG. 4B shows that a cover plate (400) can include spring clips/powerextractors (402 a, 402 b) that include a first resilient conductor (403a) and a second resilient conductor (403 b) (collectively “resilientconductors 403”). In at least one implementation, the resilientconductors (403) can allow the cover plate (400) to draw power (i.e.,the resilient conductors (403) come in contact with the powerterminals/screw terminals of the outlet/electrical receptacle, drawingpower as needed, as described above).

FIG. 4B also shows that the cover plate (400) can include a firstflexible insulating cover (404 a) and a second flexible insulating cover(404 b) (collectively “insulating covers 404”). In at least oneimplementation, the flexible insulating covers (404) can prevent theresilient conductors (403) from forming a circuit with externalmaterials. For example, as the resilient conductors (403) come incontact with the power terminals/screw terminals of theoutlet/electrical receptacle, they bend outward. This flexibilityensures that the resilient conductors (403) remain in contact with thepower connectors/screw terminals. However, it can also force theresilient conductors (403) toward the wires, the electrical box or othermaterials in the area. By adding the insulating covers (404) to theresilient conductors (403), the resilient conductors (403) can beprevented from making undesirable contact with the wires, electrical boxor other materials. In addition, the insulating covers (404) may preventarcing if the resilient conductors (403) get too close to the wires,electrical box or other materials.

FIG. 4B further shows an active cover plate (400) that includes a faceplate (405), a circuit board (435), and a back plate (430). The circuitboard (435) is sandwiched between the face plate (405) and the backplate (430). The spring clips/power extractors (402) in this exampleinclude the arc shaped resilient conductors (403) extending from thecircuit board (435) through the back plate (430). In this example, thereare no insulating tabs. The insulating covers (404) may be flexibleconformal insulation on the resilient conductors (403) to preventundesirable electrical contact with surrounding material. The flexibleconformal insulation may be any of a number of materials. In someexamples, the conformal insulation may be a polymer material that is dipcoated, brushed, or sprayed onto the resilient conductors (403) or theinsulation may be heat shrink tubing placed over the resilientconductors (403). In one implementation, the entire surface of theresilient conductors (403) may be coated with the conformal insulation(404). Selected portions of the conformal insulation may then be removedto make electrical connections between the resilient conductors (403)and the circuit board (435) and to create the exposed portion (420) thatcontacts an electrified portion of the outlet/electrical receptacle.

FIG. 4C shows a cross sectional diagram of an active cover plate (406)that includes a back plate (430) with integrally molded insulating tabs(415). The insulating tabs (415), resilient conductors (410) andconformal insulation (425) make up the power extractors (407 a, 407 b).The insulating tabs (415) are located between the resilient conductors(410) and the edge of the active cover plate (406) to preventundesirable contact between the resilient conductors (410) andsurrounding materials.

For example, the insulating tabs (415) may prevent the resilientconductors (410) from contacting the electrical box that theoutlet/electrical receptacle is installed in. In many commercialinstallations, the electrical box is metal and if a resilient conductor(410) were to contact the metal box, it could cause a short. In theembodiment shown in FIG. 4C, the resilient conductor (410) is protectedfrom electrically shorting to the electrical box by both the insulatingtab (415) and by the insulating coating (425) over the resilientconductor (410). The insulating tab (415) may be flexible so that it canconform around or deflect when obstacles are encountered. For example,sheet rock may protrude over the edge of the electrical box. Because theinsulating tab (415) is flexible, it can deform around this obstructionand still allow the cover plate (406) to correctly fit to theoutlet/electrical receptacle and still provide the desired insulatingfunction.

In some embodiments, the insulating tabs may have a height and widthgreater than the height and width of the resilient conductor. Thisensures that the resilient conductor, while being able to be deflectedindependently from the insulating tabs, cannot be deflected so far thatit contacts materials that are external to the cover plate andreceptacles (i.e. the outlet box or wall materials). The insulating tabsmay be formed in a variety of ways. For example, the insulating tabs maybe integrally molded components of a back plate that connects to theface plate. In other implementations, the insulating tabs may be formedseparately and be mechanically connected to either the face plate or theback plate. In other embodiments, the insulating tabs may have a hingedconnection with either the face plate or the back plate such that duringshipping or storage the insulating tabs lie flat, but duringinstallation and use the insulating tabs are locked in an extendedposition.

The active cover plate (406) includes two resilient conductors (410)with exposed portions (420) on their inner sides. The resilientconductors (410) face each other and are configured to contact terminalson either side of an outlet/electrical receptacle. In oneimplementation, the distance (422) between the exposed portions (420) ofthe resilient conductors (410) is less than a distance between outersurfaces of a first electrical terminal and an outer surface of a secondelectrical terminal of the outlet/electrical receptacle. At least aportion (418) of the resilient conductors (410) are angled outwardtoward the edges of the face plate (405), such that contact between theoutwardly angled portions and the outlet/electrical receptacle deformsthe resilient conductors (410) outward and positions the exposedportions (420) to contact electrical terminals on the outlet/electricalreceptacle.

Although the power extractors illustrated in FIGS. 4A-4C show insulatedconductive strips with insulating tabs, other types of power extractorscould be used. For example, the power extractors may include aninsulating tab and a resilient conductor without an insulating coveringor may include an insulated conductor without the insulating tab. Inother implementations, the power extractors may include one or moreinductive coils.

Thus in one implementation, an active cover plate may include a faceplate, a load, and electrically insulated power extractor extendingrearward from the face plate to interface with an outlet/electricalreceptacle, wherein the power extractor extracts electrical power fromthe outlet/electrical receptacle to energize the load. A face plate is aportion of an active cover plate that is exposed to view by a user whenthe active cover plate is fastened over an outlet/electrical receptacle.The load is any element or combination of elements that consumeselectrical power. A variety of loads are described above, such as lightsensors, lights, motion detectors, resistors, diodes, sensors,communication modules, speakers, and other loads. As used in thespecification and appended claims, the term “electrically insulatedpower extractor” refers to mechanisms that extract power from anoutlet/electrical receptacle. Specifically, “electrically insulatedpower extractor” refers to:

1) A resilient conductor insulated by a flexible insulating cover thatencapsulates the resilient conductor except for exposed portionconfigured to electrically contact a terminal of an electricalreceptacle;

2) A resilient conductor insulated by an insulating tab extendingrearward from the face plate, wherein the insulating tab is interposedbetween the resilient conductor and an edge of the face plate. Theresilient conductor may or may not include a flexible insulating cover.In some implementations, the insulating tab is a free standing structureseparate from the resilient conductor;

3) An encapsulated inductive coil configured to inductively extractpower from the electrical receptacle.

In each of the three embodiments of the electrically insulated powerextractor, the power extractor includes a free standing, self supportingbody. For example, the resilient conductor, the insulating tab, and theencapsulated inductive coil may all be free standing, self supportingbodies. A resilient conductor refers to an electrical resilientconductor that springs back into a predetermined shape after bending orbeing compressed. When a resilient conductor is physically restrainedfrom returning to its predetermined shape, the resilient conductorexerts a spring force on the restraining object. An electrical terminalis any conductive portion of an outlet/electrical receptacle from whichpower can be extracted or deposited. For example, a hot terminal, aneutral terminal, traveler terminals, and grounds are all electricalterminals. Screws and/or tabs on the side of an outlet/electricalreceptacle are electrical terminals.

FIGS. 5A, 5B, and 5C show a front view of a single pole light switch(500), a rear view of an active cover plate (520) configured to be usedover a single pole light switch (500), and a rear view of an activecover plate (540) configured to be used on a multi-pole light switch.

FIG. 5A illustrates an example of a switch (500). In at least oneimplementation, the switch (500) can provide power to an external devicewhich a user desires to turn on and off. For example, the switch (500)is configured to allow a user to control whether a device connected tothe switch is on or off. The switch (500) can be hardwired to the deviceor can be connected via an outlet and plug or through some otherindirect connection.

FIG. 5A shows that the switch (500) can include a body (502). In atleast one implementation, the body (502) can include a movable portionthat allows the user to control the state of the connected electricaldevice. For example, the body (502) can include a toggle, which can bemoved as desired to change the on/off state of the connected electricaldevice. Additionally or alternatively, the body (502) can include abutton, or touch screen or some other mechanism for detecting usercontrol.

FIG. 5A also shows that the switch (500) can include a bore (504). In atleast one implementation, the bore (504) is configured to receive theattachment of a cover plate. In particular, the bore (504) can allow theattachment of the cover plate to secure the cover plate relative to theswitch (500). For example, the bore (500) can include a threaded openingfor receiving a screw or any other device for the cover plateattachment. The cover plate can be configured to mate with the body(502) in order to maintain the proper orientation.

FIG. 5A further shows that the switch (500) can include a first mountingpiece (506 a) and a second mounting piece (506 b) (collectively“mounting pieces (506)”). In at least one implementation, the mountingpieces (506) are configured to attach the switch (500) to an electricalbox. For example, the mounting pieces (506) secure the switch (500) inplace, ensuring that it does not move or otherwise reorient as the useroperates the portion of the body (502) which allows the user to changethe on/off state of the connected electrical device. The mounting pieces(506) can include “yokes” or tabs that are configured to prevent theswitch (500) from being installed too deeply into the electrical box(i.e., the yokes can keep the mounting pieces (506) approximately flushwith the wall during installation).

FIG. 5A additionally shows that the switch (500) can include a powerscrew (508). In at least one implementation, the power screw (508)allows the switch (500) to be connected to an active power source.Additionally or alternatively, the power screw (508) can allow theswitch (500) to be connected to other active loads, such as additionalswitches, outlets or any other active load. The switch (500) may includea power input which allows a wire to be inserted directly without theneed to attach the wire to the power screw (508). One of skill in theart will appreciate that such inputs remain connected to the power screw(508) such that a wire from another active load and connected to thepower screw (508) is able to provide power to the additional activeload.

FIG. 5A also shows that the switch (500) can include a neutral screw(510). In at least one implementation, the neutral screw (510) returnspower to the power source, completing the electrical circuit. Forexample, power flows from the power source to the power screw (508),through the switch (500), to the neutral screw (510) and back to thepower source forming an electrical circuit. Additionally oralternatively, the neutral screw (510) can allow the switch (500) to beconnected to other active loads, such as additional switches, outlets orany other active load. The switch (500) may include a power input whichallows a wire to be inserted directly without the need to attach thewire to the neutral screw (510). One of skill in the art will appreciatethat such inputs remain connected to the neutral screw (510) such that awire from another active load and connected to the neutral screw (510)is able to provide power to the additional active load.

One of skill in the art will appreciate that the power screw (508) andthe neutral screw (510) can be of any desired voltage. For example,voltage can include 100 V, 120 V, 220 V, 230 V or any other desiredvoltage.

FIG. 5B illustrates an alternative example of a cover plate (520). FIG.5B illustrates a rear perspective view of the cover plate (520). In atleast one implementation, the cover plate (520) can be used with analternative electric device, such as a light switch. One of skill in theart will appreciate that the cover plate (520) can be configured for useat any electrical box.

FIG. 5B shows that the cover plate (520) can include a face plate (522).In at least one implementation, the face plate (522) can mate with theswitch to prevent access to the electrical box in which the switch ismounted. For example, the face plate can, in combination with theswitch, prevent access to the wires and connections within theelectrical box. The face plate (522) can include an insulating materialto prevent electrocution of a user. For example, the face plate (522)can include plastic. The face plate (522) can be a single color or caninclude designs as desired.

FIG. 5B also shows that the cover plate (520) can include one or moreapertures (524). In at least one implementation, the one or moreapertures (524) can provide access to the switch. For example, the coverplate (520) may cover a portion of a switch, but allows access toanother portion. For example, the face plate (522) can prevent access toelectrical connections or wiring. In contrast, the one or more apertures(524) can allow access to the actual switch.

FIG. 5B also shows that the cover plate (520) can include an attachment(526). In at least one implementation, the attachment (526) can includea screw hole or attached screw. The screw then is inserted into a borein the switch or electrical box which holds the cover plate (520) inplace relative to the switch. Additionally or alternatively, theattachment (526) can include one or more tabs that are attached to theswitch or electrical box. For example, the tabs are inserted into a holein the switch or electrical box and are retained by a flange or othermechanism within the switch or electrical box.

FIG. 5B additionally shows that the cover plate (520) can include afirst conducting strip (528 a) and a second conducting strip (528 b)(collectively “conducting strips (528)”). In at least oneimplementation, the conducting strips (528) can allow the cover plate todraw power. For example, the conducting strips (528) come in contactwith the power connectors of the switch, drawing power as needed, asdescribed below.

FIG. 5B also shows that the cover plate (520) can include a firstinsulating tab (530 a) and a second insulating tab (530 b) (collectively“insulating tabs” (530)). In at least one implementation, the insulatingtabs (530) can prevent the conducting strips (528) from forming acircuit with external materials. For example, as the conducting strips(528) come in contact with the power connectors of the switch, they bendoutward. This flexibility ensures that the conducting strips (528)remain in contact with the power connectors. However, it can also forcethe conducting strips (528) toward wires, the electrical box or othermaterials in the areas. The insulating tabs (530) prevent the conductingstrips (528) from contacting the wires, electrical box or othermaterials. In addition, the insulating tabs (530) prevent arcing if theconducting strips (528) get too close to the wires, electrical box orother materials.

The insulating tabs (530) can be the same material as the face plate(522) or can be attached to the face plate (522). For example, the faceplate (522) and the insulating tabs (530) can be constructed of a singlepiece of insulating material. Additionally or alternatively, theinsulating tabs (530) can be manufactured separately and then attachedto the face plate (522). The cover plate (520) may include a variety ofelectrical loads as described above.

FIG. 5C illustrates an alternative example of a cover plate (540). In atleast one implementation, the cover plate (540) can be used with analternative electric device, such as a 3-way light switch. For example,modifications to the cover plate (540) can allow for connection to anydesired device within an electrical box, even though the actual wiringconfiguration may vary depending on the device.

FIG. 5C shows that the cover plate (540) can include a face plate (542).In at least one implementation, the face plate (542) can mate with the3-way switch to prevent access to the electrical box in which the 3-wayswitch is mounted. For example, the face plate (542) can, in combinationwith the 3-way switch, prevent access to the wires and connectionswithin the electrical box. The face plate (542) can include aninsulating material to prevent electrocution of a user. For example, theface plate (542) can include plastic. The face plate (542) can be asingle color or can include designs as desired.

FIG. 5C also shows that the cover plate (540) can include one or moreapertures (544). In at least one implementation, the one or moreapertures (544) can provide access to the 3-way switch. I.e., the coverplate (540) covers a portion of the 3-way switch, but allows access toanother portion. For example, the face plate (542) can prevent access toelectrical connections or wiring. In contrast, the one or more apertures(544) can allow access to the actual 3-way switch.

FIG. 5C further shows that the cover plate (540) can include anattachment (546). In at least one implementation, the attachment (546)can include a screw hole or attached screw. The screw then is insertedinto a bore in the 3-way switch or electrical box that holds the coverplate (540) in place relative to the 3-way switch. Additionally oralternatively, the attachment (546) can include one or more tabs thatare attached to the 3-way switch or electrical box.

FIG. 5C additionally shows that the cover plate (540) can include afirst conducting strip (548 a), a second conducting strip (548 b) and athird conducting strip (548 c) (collectively “conducting strips (548)”).In at least one implementation, the conducting strips (548) can allowthe cover plate (540) to draw power. For example, the conducting strips(548) come in contact with the power connectors of the 3-way switch,drawing power as needed, as described below.

FIG. 5C also shows that the cover plate (540) can include a firstinsulating tab (550 a), a second insulating tab (550 b) and a thirdinsulating tab (550 c) (collectively “insulating tabs (550)”). In atleast one implementation, the insulating tabs (550) can prevent theconducting strips (548) from forming a circuit with external materials.For example, as the conducting strips (548) come in contact with thepower connectors of the 3-way switch, they bend outward. Thisflexibility ensures that the conducting strips (548) remain in contactwith the power connectors. However, it can also force the conductingstrips (548) toward wires, the electrical box or other materials in thearea. The insulating tabs (550) prevent the conducting strips (548) fromcontacting the wires, electrical box or other materials. In addition,the insulating tabs (550) prevent arcing if the conducting strips (548)get too close to the wires, electrical box or other materials.

The insulating tabs (550) can be the same material as the face plate(542) or can be attached to the face plate (542). For example, the faceplate (542) and the insulating tabs (550) can be constructed of a singlepiece of insulating material. Additionally or alternatively, theinsulating tabs (550) can be manufactured separately and then attachedto the face plate (542). FIG. 5C further shows that the cover plate(540) can include a load (552). In this example and as discussed above,the load may include 3 LEDs spaced along a bottom edge of the activecover plate (540).

FIG. 6A describes one illustrative construction of the active coverplate (600) and its connection to the outlet body (602). As discussedabove, spring clips (608 a, 608 b) engage with screws (606) on the sidesof the outlet (602). The spring clips (608 a, 608 b) bring power to allof the circuitry/modules (614) that may be contained within the activecover plate (600). In this example, the circuitry (614) may include LEDlighting. The spring clips (608 a, 608 b) may be secured to the faceplate (604) in a variety of ways. In this example, the metal base (612)of the spring clips (608 a, 608 b) fits over posts (e.g. 610) extendingout of the back of the face plate (604). The metal base (612) may thenbe secured by press nuts (611) that fit over the posts (610), by heatstaking the posts, or by cold pressing the posts.

The circuitry (614) may include a printed circuit board (PCB) with avariety of components such as LEDs, a sensor, and a power supply. TheLEDs may be mounted directly to the PCB and light from the LEDs isdirected to the desired apertures in the face plate (604) using lightpipes. There can be any number of LEDs included in the design. In thisexample, there are 3 or 4 LED/light pipes. Although this example showsthe circuitry (614) located only at the bottom of the outlet cover, thecircuitry (614) could have a variety of configurations, including a “U”shaped PCB that extends up the sides to the spring clip locations. Thismay allow for the circuitry (614) to be placed along the sides of theoutlet (602) and the lower portion of the PCB to only contain the LEDs.This can provide additional clearance for the metal bracket on thebottom of the outlet (602) by removing the portion of the PCB that isbetween the outlet (602) and the inner surface of the face plate (604).

FIG. 6B is a detail perspective view of the spring clip (608), its base(612), the posts (610) and press nuts (611) on the posts. In thisexample, the spring clip (608), base (612), and conductor (613) to thecircuitry (614, FIG. 6A) are formed from a single piece of a resilientmetal sheet. After the metal sheet is cut into the desired shape,including a strip that will form the spring clip (608) and holes toreceive the posts (610), the strip is formed into the spring clip (608).This may be done in a variety of ways, including stamping processes. Inthis example, the spring clip (608) has a sinusoidal shape, with aconvex base curve (616), a concave mid curve (618), and an upper convexcurve that contains the contact region (624) and an angled flange (622)to guide the spring clip (608) over the screws. In this example, thebase curve (616), mid curve (618), and angled flange (622) are coveredby electrical insulation (626). Although the entire spring clip (608)may flex, the majority of the bending may occur in the base curve (616).The mid curve (618) provides additional clearance away from the outletbody.

The contact region (624) includes a compound curvature with two wings(620) that extend to the left and right of the center of the contactregion (624). The wings (620) allow the spring clip (608) to movevertically up and down after the cover plate (600, FIG. 6A) has beenplaced over the outlet (602, FIG. 6A). In some instances, users mayinitially place the cover plate (600) too high or low on the outlet(602). After engaging the spring clips/prongs (608) with the sides ofthe outlet (602), the user may then move the cover plate (600)vertically into the correct position. This moves the spring clips (608)over the sides of the outlet (602). To prevent the spring clip (608)from snagging or being caught during this vertical motion, the wings(620) are angled backwards to direct the spring clip (608) over theobstacle. For example, the power screws and wires connected to theoutlet (602) by the power screws may be obstacles that the springclip/prong (608) may become snagged on. The wings (620) reduce thelikelihood of snagging by directing obstacles under the spring clip(608) and producing additional deformation of the spring clip (608) sothat it can move over the obstacles. In this example, the wings (620)are not electrically insulated. The angled flange (622) is configured todirect the spring clip (608) around the outlet body (602) as the activecover plate (600) is pressed over the outlet body (602).

An outlet (602) may be installed in a receptacle box in one of twoorientations: right-side up or upside down. Outlets can be installed inthe receptacle box in either direction and still function properly.Consequently, the orientation of the outlet can be selected according tothe convenience the installer/user. The spring clips (608) in thisexample are designed to connect to the power screws on both sides of theoutlet (602) regardless of the orientation of the outlet (602). Thus, inthis example, the active cover plate (600) can be installed and operatein an upright position regardless of the orientation of the outlet(602).

FIGS. 7A and 7B show rear views of an illustrative active cover plate(700) with spring clips (704) for use over an electrical receptacle. Theembodiment shown is specifically adapted for use with a decor outlet. Inthis example, the active cover plate (700) includes a face plate (706),a back plate/sandwich plate (705) with two integral walls that areshaped like “U” channels, and spring clips (704). In this example, thesandwich plate (705) and spring clips (704) are connected to the faceplate (706) with press nuts (713) that fit over posts (710). The bases(708) of the spring clips (704) are sandwiched between the face plate(706) and the sandwich plate (705). The posts (710) are integrallymolded parts of the face plate (706). When the press nuts (713) arepressed over the posts (710), the sandwich plate (705) is forced againstthe bases (708) of the spring clips (704), firmly holding the springclips (704) in place.

FIG. 7A is a rear view of the cover plate (700). This view illustratesthat the U channel shaped wall (702) surrounds the rear and sides of thespring clips (704) and prevents accidental contact with the spring clips(704). When the active cover plate (700) is installed over an outletbody, the spring clip (704) is surrounded on all four sides. Three sidesare covered by the U channel (702) and the outlet body covers the fourthside. The walls (702) prevent the uninsulated spring clips/prongs (704)from electrically contacting exterior conductors (e.g. a metalreceptacle box or an electrical conductor in the receptacle box).

FIG. 7B shows a rear view of the cover plate (700) with the sandwichplate (705) removed to show the circuit board (712), electricalconductors (716), and spring clips (704). Each of the spring clips (704)include a base (708). In this example the base (708) has a cruciformshape with an attachment post passing through the intersection.Electrical conductors (wires) (716) are connected to each of the basesand pass down the sides of the face plate (706) to a printed circuitboard (712). The wires (716) are held in place by wire brackets (711).The wires (716) conduct electrical power to the circuit board (712) topower the functionality provided by the circuit board (712).

FIG. 8 shows a perspective view of an illustrative spring clip (708)mounted to the back of a face plate (706). The spring clip (708)includes a convex base curve (718), a concave mid curve (720), angledwings (726), an angled end portion (728), and a folded end (730). Asdiscussed above, the angled end portion (728) directs the spring clip(708) outward as the active cover plate (700) is initially brought intocontact with the outlet or switch body. Folding the end of the springclip (730) creates a smooth end shape that will not gouge or snag onsurrounding materials.

The structure of the spring clip (708) is designed to allow for largeamounts of flexibility without permanent deformation. The spring clip(7084) can be formed from a variety of different materials includingcopper alloys, spring steels and beryllium alloys. As discussed above,the spring clips (708) are designed to make electrical contact withscrew terminals on the sides of the outlet body. The screw terminals mayhave a variety of different widths, depending on the width of the outletbody and whether the screws are screwed out of the body or into thebody. In one design, for small amounts of deformation, the spring clips(708) primarily move outward by cantilever bending with most of therotation occurring in and around the base curve (718). For largeramounts of deformation, the back portions of the spring clip (708) beginto contact the inner wall of the U channel (702). This changes thebending locations within the spring clips (708) and prevents the basecurve (718) from being plastically deformed. The back portions of thespring clip (708) that may contact the U channel (702) include the backportion of the mid curve (720) and the folded end (730) of the springclip (708). These portions are designed to slide within the U channel(702) during deformation. For example, the rounded back portion of themid curve (720) and folded end (730) both present smooth roundedsurfaces that will slide easily in the U channel (702) without becomingcaught. The spring becomes much stiffer when the back of the mid curve(720) and folded end (730) contact the back of the U channel (702). Thebending then occurs in different areas than the base curve (718). Forexample, a significant amount of the additional bending may occur inregions that are immediately above and below the angled wings (726).

The angled wings (726) are portions of the spring clip (708) that arebent at an acute angle back over the front of the body of the springclip (708). Together, the two folded wings (726) form a pyramid likeshape that directs the spring clip (708) over obstructions on the sideof the outlet or switch body. For example, when the rounded edges of thewings (726) encounter a screw during the initial placement of the activecover plate (700) over the outlet body, the rounded edges will push thespring clip (708) backward to pass over the screw. Similarly, theoutward faces of the wings (726) will direct the spring clip (708) overobstructions (such as screws, wires, and contours of the outlet body)when the active cover plate (700) is moved vertically during adjustmentof the position of the active cover plate (700) after it has been pushedover the outlet or switch body. The angled wings (726) create a stiffportion in the center of the spring clip (708). Bending will primarilyoccur at locations other than this stiffer portion. The angled wings(726) are the portion of the spring clips (708) that extend the farthestinward toward the center of the active cover plate (700) and will be theportion of the spring clip (708) that directly engages the screwterminals in most embodiments.

In some implementations, the edges and/or outward facing faces of thewings (726) may have a number of grooves (724) or other texturing. Insome examples, this texture may be used to remove paint, primer, andother insulating material from the screws or screw terminals. In theexample shown in FIG. 8, there are grooves (724) across the edges of thewings (726). When the spring clips (708) are inserted over the body ofthe outlet, the edges of the grooves (724) and ridges between thegrooves (724) scrape over the surface of the screws. Because only verysmall pointed portions of the spring clip (708) contact the paintedsurface, they can be relatively effective in cutting through andscraping off the paint to make electrical contact with the underlyingscrews. The active cover plates (700) draw power on the order ofmilliamps from the side terminals. Consequently, large contact areas forelectrical conduction are not required. One or more point contacts witheach screw terminal can be sufficient to safely and reliably draw thedesired amounts of power from the screw terminals.

The U channel (702) provides a number of benefits as it interacts withthe spring clip (708). It shields the screw terminal from accidentalcontact with exterior devices or components. The U channel (702) alsoprevents undesirable plastic bending of the spring clip (708) bysupporting the spring clip (708). For example, when the folded end (730)of the spring clip (708) is between the side walls of the U channel(702), lateral forces (for example, forces exerted on the spring clip(708) during vertical motion relative to the outlet body) will not bendthe spring clip (708) to the side.

Embodiments that use the U channel (702) shaped wall or other similarinsulating shielding or tab may not require insulation placed directlyon the spring clip (708). In the example shown in FIGS. 7A, 7B, and 8,the spring clip (708, FIG. 8; 704 FIG. 7A) does not have any insulatingcoating because it is protected and insulated from the surroundings bythe wall. In other embodiments, walls may be used in conjunction with aninsulated spring clip.

FIGS. 9A, 9B, and 10 show views of an illustrative active cover plate(900) for use over an electrical receptacle such as a decor outletreceptacle. The principles described can be applied to a wide variety ofactive cover plates including active cover plates for duplex outlets andlight switches. In this example, the active cover plate (900) includesspring clips or “power extractors” (904) with non-conductive portions(922, FIG. 10) that extend significantly beyond the electrical contactpoint (see e.g. FIG. 10). The active cover plate (900) in this exampleincludes two opposing spring clips (904) connected to a face plate(906). However, there can be any number of spring clips that arearranged in a variety of locations to make desired contact with screwsand screw terminals on the sides of outlets, light switches, or otherelectrical receptacles. The bases (908) of the spring clips aresandwiched between the sandwich/back plate (905) and the rear of theface plate (906). In this example, the non-conductive portion or ramp(922, FIG. 10) is connected to the lower conductive portion (918, FIG.10) of the spring clips (904) by a rivet (920, FIG. 10). In addition tosecuring the ramp (922, FIG. 10) to the conductive portion (920, FIG.10), the head of the rivet also serves as an electrical contact whichforms an electrical connection with the screws or terminals on the bodyof the receptacle. In one example, the rivets (920, FIG. 10) may be heldin place by swaging/expanding the backside of the rivet over/in anaperture in the lower conductive portion.

In this embodiment, there is a wall or tab (902) behind each of thespring clips (904) that limits extreme motion of the spring clip (904)and prevents conductive portions of the spring clip (904) from makingundesirable contact with exterior material. The walls or tabs (902)extend rearward from the sandwich plate (905).

FIG. 9B is a rear view of the active cover plate (900) with the backplate/sandwich plate (905, FIG. 9A) removed. This shows the bases (908)of the spring clips (904), circuit board (912), and conductor (916)connecting the spring clips (904) to the circuit board (912). In thisexample, the conductor (916) is a wire that is connected to the base(908) of the spring clip (904) by crimping, soldering, or other suitabletechnique. The wire (916) is routed through a number of wire brackets(910) that are molded into the face plate (906). The face plate (906)also includes alignment posts and press nut posts (910).

FIG. 10 shows a perspective view of an illustrative spring clip (904)mounted to the back of a face plate (906). The walls or tabs (902) arelocated between the spring clips/prongs (904) and the exterior edges ofthe face plate (906). The heads of the rivets (920) on the prongs/springclips (904) are the most inwardly extending portion of the spring clips(904).

The non-conductive portion (922) of the spring clips (904) can be formedfrom a variety of insulating materials, including polymers, ceramic,composite materials, or other material. In this example thenon-conductive portion (922) is formed from a flexible resilient polymermaterial such as nylon. The non-conductive portion (922) can be formedin a variety of ways, including injection molding.

The non-conductive portion (922) is attached to the terminal end of theconductive portion (918) by the rivet (920). Additionally oralternatively, a number of other techniques can be used to attach thenon-conductive portion (922). For example, the non-conductive portion(922) may be joined to the conductive portion (918) by adhesive, heatwelding, press fit, snap fit, induction welding (for specific types ofmaterials), ultrasonic welding/staking, and other suitable techniques.These techniques can be used separately or in combination. For example,the rivet joint may be supplemented by interaction of the conductiveportion (918) with molded features on the non-conductive portion (922).As discussed above, the riveted connection between the non-conductiveportion (922) and conductive portion (918) has a number of advantages,including using the head of the rivet (920) as a contact point and theswaging of the rivet (920) into/over a hole in the conductive portion(918) to ensure that there is a reliable electrical connection betweenthe rivet (920) and the conductive portion (918).

The non-conductive ramp portion (922) can serve a variety of functions.In this example, the non-conductive portion (922) includes an angled endportion (924) (“ramp”), a terminal curve (926) and two wings (928) thatextend to either side of the central body/rivet (920) of the spring clip(904). First, the non-conductive portion (922) serves as a guide thatdirects the cover plate (900, FIG. 9A) into accurate positioning overthe outlet/receptacle body. Where there are opposing spring clips (904),the angled ramp (924) guides and centers the cover plate (900) over theoutlet/receptacle body. In situations where the cover plate (900, FIG.9A) is misaligned such that the non-conductive portion (922) contactsthe wall of an enclosure, the terminal curve/end (926) ensures that thespring clip (904) glides smoothly along the wall. The spring force ofthe conductive portion (918) and non-conductive portion (922) gentlyguides the cover plate (900, FIG. 9A) into place with increasingaccuracy as the cover plate (900, FIG. 9A) is pushed closer to its finalposition.

Second, the non-conductive portion (922) is contoured so that theelectrical contact (the head of the rivet (920)) doesn't have anyexposed edges that may snag on the outlet body, wires, or screws. Third,the wings (928) allow for the spring clip (904) to glide up and downover the screws and screw terminals. As discussed above, there may bevertical misalignment between the active cover plate (900, FIG. 9A) andthe receptacle body during the installation process. To achieve thedesired alignment and to allow the active cover plate (900, FIG. 9A) tofit around the face of the receptacle body and to align the fasteneraperture in the cover plate (900, FIG. 9A) with the threaded hole in theoutlet body, the active cover plate (900, FIG. 9A) may be slid up anddown. The wings (928) and smooth contours of the spring clip (904) arecreated by molding the central portion of the non-conductive portion(922) to match/mate with the surface of the installed rivet (920). Thesewings (928) and smooth contours allow the spring clip (904) to glidesmoothly over the screws. The wings (928) progressively bend the springclip (904) backwards to lift it over obstacles (such as screw heads andcontours of the receptacle body).

The characteristics of the spring clip (904) shown in FIG. 10 include anangled conductor portion (918), with the angle of the conductor portion(918) directing the rivet (920) inward toward the outlet body. The rivet(920) is the most prominent portion of the spring clip (904) and extendsfarthest inward toward the outlet body. Both the wings (928) and themain ramp (924) are angled away from the outlet body, with the base ofthe wings (928) and ramp (924) joining with the center of thenon-conductive portion (922) containing the rivet (920) and the endsextending away from the outlet body.

The conductive portion (918) in this example includes simple curveswhere the conductive portion (918) passes under the sandwich plate (905)and a simple curve where the conductive portion (918) contacts/joins thenon-conductive portion (922). The conductive portion (918) may be madefrom a variety of materials including steels, copper, and alloysthereof. For example, the conductive portion (918) may be formed from aberyllium copper alloy. Alternatively the conductive portion (918) maybe formed from spring steel with a nickel coating to increase itselectrical conductivity and prevent corrosion. In some embodiments, theconductive portion (918) may be coated or covered by an insulatinglayer. The insulating layer may be created in a variety of ways,including a sleeve, a dipped layer, a brushed layer, a chemicallydeposited layer, or other technique.

FIG. 11 shows a partially cutaway bottom view of an illustrative activecover plate (900) mounted over an outlet receptacle (901) mounted in areceptacle box (903). In this example, the terminal ends (926 a, 926 b)of the non-conductive portions (922 a, 922 b) contact the inner face ofwalls (909 a, 909 b) of the box (903). This provides a number ofbenefits. First, the contact between the terminal ends (926 a, 926 b) ofthe spring clips (904 a, 904 b) and the walls (909 a, 909 b) may provideincreased resistance to further deformation. This can prevent largedeformation/bending angles that could permanently deform the conductiveportion (918 a, 918 b) of the spring clip (904 a, 904 b). Second, thecontact with the side walls (909 a, 909 b) can increase the amount ofcontact pressure between the rivet heads (902 a, 902 b) and the screws(907 a, 907 b), thereby increasing the reliability of the electricalconnection between the spring clips (904 a, 904 b) and the screws (907a, 907 b). As discussed above, the non-conductive portion (922 a, 922 b)may be formed from a resilient polymer such as nylon. This allows forsignificant deformation/spring action by the non-conductive portion (922a, 922 b). For example, if the gap between the outlet (901) and innerwall (909 a, 909 b) of the receptacle box (903) is particularly tight,the non-conductive portion (922 a, 922 b) can be almost straight.

Additionally, as shown in FIG. 11 and described above, the walls or tabs(902 a, 902 b) can limit the motion of the spring clips (904 a, 904 b)and prevent the rear side of the spring clips (904 a, 904 b) fromcontacting conductive materials. FIG. 11 shows the spring clips (904 a,904 b) contacting the walls (902 a, 902 b) as the spring clips (904 a,904 b) are bent outward by the screws. The walls (902 a, 902 b) may havea variety of heights. For example, the walls (210 a, 210 b, 415, 550 a,550 b, 550 c, 702) may be taller than the spring clips as shown in FIGS.2C, 4C, 5B, 5C, and 8 or may be shorter than the spring clips as shownin FIGS. 9A, 10 and 11. The walls may be molded directly in the faceplate, molded features on a sandwich plate/backplate, or may beseparately attached. The walls may be wider than the spring clip asshown in FIGS. 2C, 4C, 5B, 5C, and 8 or may be narrower than the springclips as shown in FIGS. 9A, 10 and 11. Further, the walls may be used inconjunction with a variety of different types of spring clips/prongs.For example, the walls may be used with spring clips/prongs that may beuninsulated (see e.g. 208 a, 208 b, FIG. 2C, FIG. 3; 548 a, 548 b, 548c, FIGS. 5B, 5C; 704, FIG. 7A; 708, FIG. 8) or insulated (see e.g. 425,FIG. 4A; 407 a, 407 b, FIG. 4C; 904, FIG. 10).

Additionally, the spring clips may be designed to contact walls ofreceptacle boxes as shown in FIG. 11. In general, contacting walls,either walls that extend from the active cover plate or walls of thereceptacle boxes, limit the motion of the spring clip to prevent damageto the spring clip and provide additional force that presses the springclip more tightly against the outlet body.

FIGS. 12, 13, 14A, and 14B show an illustrative example of an activecover plate (1200) with spring clips (1210, 1212) that fit over posts(1220) and are sandwiched between a sandwich plate/back plate (1230). Insome examples, the spring clips/prongs (1210, 1212) are adjustablevertically and in width. FIG. 12 is a rear perspective view of theactive cover plate (1200) for a “decora” style outlet body. However, theprinciples described could be used in conjunction with a wide range ofspring clips and receptacle bodies.

The active cover plate (1200) includes a face plate (1215) with anaperture (1232) through which the outlet receptacles in the outlet bodyare accessible. The active cover plate (1200) includes spring clips(1210, 1212) and a sandwich plate (1230). The spring clips (1210, 1212)include a compliant conductive portion (1235) with one end that issandwiched between the face plate (1215) and the sandwich plate (1230).In this example, a rectangular rivet (1240) and a non-conductive portion(1205) are connected to an opposite terminal end of the compliantconductive portion (1235). The spring clips (1210, 1212) and sandwichplate (1230) could be fastened to the face plate (1215) using a numberof techniques, including heat staking or using fasteners that arepressed over the posts (1220). When placed over an outlet body, therivets (1240) on the spring clips (1210, 1212) contact the electrifiedscrew terminals on the sides of the outlet body to extract power fromthe building wiring/outlet body. Although this active cover plate (1200)is only illustrated with two opposing spring clips (1210, 1212), anactive cover plate may have any number of spring clips.

The spring clips (1210, 1212) may be placed over different posts (1220)to position/secure the spring clips (1210, 1212) in the desired locationon the back of the face plate (1215). The spring clips (1210, 1212) areelectrically connected to a load in the active cover plate (1200). Inthis example, the load is a circuit board that includes three lightemitting diodes (LEDs) that shine downward and out of the active coverplate (1200) through three apertures (1242).

FIGS. 13, 14A and 14B are additional views of a spring clip (1212) thatcould be used in conjunction with the cover plate (1200, FIG. 12) shownin FIG. 12. FIG. 13 shows a front perspective view of a spring clip(1212) that includes a conductive portion (1235) and a non-conductiveportion (1205). The non-conductive portion (1205) has a main ramp(1252), side wings (1254), and a terminal curve (1250). Thenon-conductive portion (1205) may have a variety of purposes includingpreventing the conductive portion (1235) from undesirably contactingwires, the electrical box, or other materials. The non-conductiveportion (1205) may also prevent arcing between resilient conductors andexternal conductors.

The non-conductive portion (1205) of the spring clip (1212) can beformed from a variety of insulating materials, including polymers,ceramic, composite materials, or other material. In this example, thenon-conductive portion is formed from a flexible resilient polymermaterial such as nylon. The non-conductive portion (1205) can be formedin a variety of ways, including injection molding.

In this example, the non-conductive portion (1205) is attached to theterminal end of the conductive portion (1235) by the rivet (1240).Additionally or alternatively, a number of other techniques can be usedto attach the non-conductive portion (1205) to the conductive portion(1235). For example, the non-conductive portion (1205) may be joined tothe conductive portion (1235) by adhesive, heat welding, press fit, snapfit, induction welding (for specific types of materials), ultrasonicwelding/staking, and other suitable techniques. These techniques can beused separately or in combination. For example, the rivet joint may besupplemented by molded features on the non-conductive portion (1205). Asdiscussed above, the riveted connection between the non-conductiveportion (1205) and conductive portion (1235) has a number of advantages,including using the head of the rivet (1240) as a contact point and theswaging of the rivet (1240) into/over a hole in the conductive portion(1235) to ensure that there is a reliable electrical connection betweenthe rivet (1240) and the conductive portion (1235).

The non-conductive portion (1205) can serve a variety of functions. Asdiscussed above, the non-conductive portion (1205) includes an angledend portion or a main ramp (1252), a terminal curve (1250) and two sidewings (1254) that extend to either side of the central portion of thespring clip (1212). The non-conductive portion (1205) serves as a guidethat directs the active cover plate (1200, FIG. 12) into accuratepositioning over an outlet/switch body. Where there are opposing springclips (1210, 1212, FIG. 12), the angled ramp (1252) guides and centersthe active cover plate (1200, FIG. 12) over the outlet/switch body. Insituations where an active cover plate (1200, FIG. 12) is misaligned orhas less clearance, the non-conductive portion (1205) may contact thewall of an electrical box. The terminal curve (1250) ensures that thespring clip (1212) glides smoothly along the wall. The spring force ofthe conductive portion (1235) and ramp geometry of the non-conductiveportion (1205) guides the active cover plate (1200, FIG. 12) into placewith increasing accuracy as the active cover plate (1200, FIG. 12) ispushed closer to its final position.

The non-conductive portion (1205) is contoured so that the electricalcontact (the head of the rivet (1240)) does not have any exposed edgesthat may snag on the outlet body, wires, or screws. The side wings(1254) allow for the spring clip (1212) to glide up and down over thescrews and screw terminals. As discussed above, there may be verticalmisalignment between the active cover plate (1200, FIG. 12) and thereceptacle body/screw terminals during the installation process. Toachieve the desired alignment, to allow the active cover plate to fitaround the face of the receptacle body and to align the fasteneraperture in the cover plate with the threaded hole in the outlet body,the active cover plate may be slid up and down with respect to thereceptacle body. For example, a user may have engaged the active coverplate too low on the receptacle body and needs to move it up to alignthe cover plate with the outlet body. The side wings (1254) and smoothcontours of the spring clip (1212) created by molding the centralportion of the non-conductive portion (1205) to match/mate with thesurface of the installed rivet (1240) allow the spring clip (1212) toglide smoothly over the screws. The side wings (1254) progressively bendthe spring clip (1212) backwards to lift it over obstacles (such asscrew heads and contours of the receptacle body).

In this example, the head of the rivet (1240) is rectangular, with themajor axis of the rectangular head oriented to provide contact withscrew terminals/screws that have a variety of depths (distances from thefront face of the outlet body). The narrow width of the rivet head(1240) reduces the likelihood of arcing if the screw terminal has beendivided into two separate electrical elements by removing the brake-outin the middle of the screw terminal. This geometry is only one example.A variety of other electrical contact geometries could be used.Additionally, the flexible conductive portion (1235) is angled inward topresent the rivet head (1240) at a desired angle and to provide for alarge range of motion of the spring clip (1212) outward. Thisaccommodates receptacle bodies of varying width and screws that arescrewed outward from the screw terminals.

FIG. 14A is a side view of the spring clip (1212) that shows variouscomponents of the flexible conductive portion (1235). In this example,the flexible conductive portion (1235) includes a base portion (1262),an “S” shaped curve (1264) connected to the base portion (1262), and anangled portion (1263). The angled portion (1263) directs the rivet(1240) inward toward the outlet body. The rivet (1240) is the mostprominent portion of the spring clip (1212) and extends farthest inwardtoward the outlet/receptacle body. Both the side wings (1254) and themain ramp (1252) are angled away from the outlet body, with the base ofthe side wings (1254) and ramp (1252) joining with the center of thenon-conductive portion (1205) containing the rivet (1240) and the endsof the side wings (1254) and ramp (1252) extending away from the outletbody.

The flexible conductive portion (1235) may include a variety of compoundcurves that increase its flexibility and resilience in allowing themotion/travel of the spring clip (1212) toward and away from theoutlet/switch body (width adjustment). One example of this is the “S”shaped curve (1264). The “S” shaped curve (1264) serves severalfunctions. The “S” shaped curve (1264) provides increased flexibility tothe spring clip (1212) by providing two separate curvatures that bend.The “S” shaped curve (1264) also allows for more bending/travel of thespring clip (1212) before permanent deformation of the conductiveportion (1235) because the bending is distributed over two locationsrather than one.

FIG. 14B shows a rear perspective view of the spring clip (1212). Theend of the conductive portion (1235) has a reduced width and interfaceswith the non-conductive portion (1205). The center of the conductiveportion (1235) with reduced width has an aperture through which the rearof the rivet (1240) passes. The rear of the rivet (1240) is then swaged(mushroomed) over the aperture as shown in FIG. 14B to make theconnection between the flexible conductive portion (1235) and thenon-conductive portion (1205). In this example, the nonconductiveportion (1205) also includes a skirt (1260) that covers the rear of theconductive portion (1235) and prevents undesirable electrical contactand arcing.

The width of the conductive portion may create a significant resistanceto twisting or bending forces that would tend to undesirably move thespring clip back and forth toward the top/bottom of the active coverplate. This undesired motion tends to occur when the active cover plateis being moved vertically with respect to the outlet/switch body and thespring clip is moving over the screws/screw terminals. The relativelyhigh stiffness of the spring clip in this direction preventstwisting/deformation during this operation, while the much lowerstiffness of the spring clip in the perpendicular direction (motiontoward and away from the screw terminals) allows for the spring clip tomove smoothly over the screws/screw terminals.

FIG. 14B also shows how the spring clip (1212) is secured to the faceplate (1215) and makes an electrical connection with the wire (1244).The spring clip (1212) includes a base portion (1262) with a number ofapertures. The apertures are configured to receive various alignment andanchor features that are molded into the face plate (1215). As discussedabove, there are number of posts (1248) in the face plate (1215). In oneembodiment, the apertures in the base portion (1262) are configured toaccept two adjacent posts (1248). In this example, the spring clip(1212) has been placed over the second and third posts (1248-2, 1248-3).By selecting which posts (1248) the apertures are placed over, thevertical position of the spring clip (1212) can be selected duringmanufacturing without having to manufacture different face plates(1215), spring clips (1212) or sandwich plates. The connection betweenthe wire (1244) and the spring clip (1212) can be made using a wireattach feature (1266) on the base portion (1262). The wire attachfeature (1266) may include a slot into which a stripped conductor can beplaced. The conductor can then be soldered to the wire attach feature(1266). The wire (1244) can be cut to the desired length or can be longenough to accommodate all vertical positions of the spring clips (1212).

FIG. 15 is an exploded assembly view of a spring clip (1650) that showsan illustrative conductor (1600) and insulator (1500) that fits over theconductor (1600). In this example, the insulator (1500) is formed from asingle piece of electrical insulating material and includes an upperportion (1540), a rear insulating portion (1515), and a front insulatingportion (1530). The upper portion (1540) includes a main ramp (1505),and two side ramps (1510). It also includes a cavity (1522) to receivethe contact (1605). In this embodiment, the rear insulating portion(1515) is directly connected to the upper portion (1540). The rearinsulating portion (1515) is connected to the front insulating portion(1530) by a flexible portion (1525). For example, the flexible portion(1525) may be a joint or a living hinge. In one example, the rearinsulating portion (1515) includes an aperture (1520) that is configuredto receive a post (1535) on the front insulating portion (1530).

The front insulating portion (1530) is folded upward as shown by thecurved arrow. In this example, the cavity (1522) in the upper portion(1540) of the insulator (1500) slips over the contact (1605) and thebarbs (1625) engage with the sides of the cavity (1522) to secure theinsulator (1500) onto the conductor (1600). The front insulating portion(1530) is then rotated about the joint (1525) until the post (1535) fitsthrough the aperture (1630) in the flexible conducting portion (1610)and through the aperture (1520) in the rear insulating portion (1515).The post (1535) is then secured in place. For example, the post (1535)may be pressed so that it expands to fill the apertures (1520, 1630) andsecure the front insulating portion (1530) to the rear insulatingportion (1515) and additionally secure the insulator (1500) to theconductive element (1600).

FIGS. 16A and 16B are a perspective view and top view, respectively, ofthe illustrative spring clip (1650) shown in FIG. 15. FIG. 16A shows aperspective view of a spring clip (1650). In this view, thehood/insulator (1500) is installed over the conductor (1600), so thatthe ramps (1505, 1510) allow the contact (1605) to move into place overthe screw terminal. The front insulating portion (1530) covers the frontof the flexible conductive portion (1610) and the rear insulatingportion (1515) covers the rear of the flexible conductive portion(1610). Thus, the flexible conductive portion (1610) is sandwichedbetween the front insulating portion (1530) and the rear insulatingportion (1515).

FIG. 16B shows a top view of the spring clip (1650), showing the post(1535) extending through the apertures and out of the rear insulatingportion (1515). The post (1535) is then secured in place by any of anumber of means, including swaging, compressing, adhesive, or any othersuitable means. Once it is secured in place, the front insulatingportion (1530, FIG. 16A) and the rear insulating portion (1515) sandwichthe flexible conductive portion (1610, FIG. 16B) between them.

Thus, in a first exemplary embodiment, a system in accordance with thepresent invention may comprise an active cover plate including one ormore of the following structures: (1) a face plate; (2) an electricalload; (3) at least one clip extending rearward from the faceplate, theclip comprising one or more of: a contact; a resilient strip supportingthe contact, wherein the contact is joined to the resilient strip andpasses through the resilient strip; and a rear insulator covering a rearside of the contact; and (4) an electrical connection between the clipand the electrical load.

Such an active cover plate may also include one or more structures setforth above combined with one or more of: (1) the resilient stripcomprising a base, a bend, and an upright portion; (2) the rearinsulator moving with respect to the main upright portion when the mainupright bends; (3) the rear insulator covering at least a portion of thebend and the upright portion; (4) a back plate, wherein the rearinsulator comprises an integrally molded feature of the back plate; (5)the integrally molded feature comprising a wall; (6) the integrallymolded feature comprising a hinged connection to the back plate; (7) aback plate, wherein the resilient strip comprises a base sandwichedbetween the back plate and the face plate; (8) the face plate comprisingposts extending rearward and wherein the back plate and base compriseapertures to accept the posts, the posts securing the base of theresilient strip between the face plate and the back plate; (9) the postsbeing compressed to secure the back plate to the face plate; (10) thecontact comprising a major axis and a minor axis, wherein the major axisis at least 20% greater than the minor axis; and (11) the major axisbeing substantially perpendicular in at least one direction to a rearplane of the face plate.

In a second exemplary embodiment, a system in accordance with thepresent invention may comprise an active cover plate including one ormore of the following structures: (1) a face plate; (2) an electricalload; (3) a clip extending rearward from the face plate to interfacewith screw terminals of a receptacle body, wherein the clip comprisesone or more of (a) a contact, (b) a conductor connected to the contact,(c) a front insulator, and (d) a rear insulator, wherein the conductoris disposed between the front insulator and the rear insulator; and (4)an electrical connection between each of the contact and the electricalload.

Such an active cover plate may also include one or more structures setforth above combined with one or more of: (1) the rear insulator beingjoined to the front insulator; (2) the rear insulator covering a rear ofthe contact; (3) a back plate, wherein the rear insulator comprises amolded feature of the back plate; and (4) the conductor being sandwichedbetween the front insulator and rear insulator.

In a third exemplary embodiment, a system in accordance with the presentinvention may comprise an active cover plate including one or more ofthe following structures: (1) a faceplate comprising one or more of (a)three spaced apertures along one edge and posts extending rearward fromthe faceplate, (b) a load comprising at least three light emittingdiodes, wherein light emitted from the three light emitting diodes shinethrough the three spaced apertures along the one edge of the faceplate,and (c) a light sensor, wherein the light sensor receives ambient lightthrough the aperture on the face of faceplate; (2) a pair of opposingclips extending rearward from the faceplate to interface with opposingscrew terminals of an outlet receptacle body, wherein the pair ofopposing clips are configured to bend outward as the clips interfacewith the opposing screw terminals, wherein the each of the clipscomprise a contact configured to electrically contact one of theopposing screw terminals; (3) electrical connections connecting each ofthe contacts and the load; and (4) a back plate, wherein each of theclips fits over posts extending rearward from the faceplate and the backplate fits over posts to sandwich the clips between the faceplate andthe back plate, wherein the posts are compressed to secure the prongsand back plate to the face plate.

Such an active cover plate may also include one or more structures setforth above combined with one or more of: (1) a light pipe, wherein thelight pipe is configured to fit into the three spaced apertures anddirect light from the at least three light emitting diodes out throughthe three space apertures; (2) each clip comprising a main rampconfigured to guide the spring clips around the outlet receptacle body,wherein the main ramps are configured to contact a wall as the clipsbend outward and interface with the opposing screw terminals, whereincontact with the wall by the main ramp increases contact pressurebetween the contact and the screw terminal; (3) the wall comprising aninterior wall of an outlet receptacle box; (4) the wall comprising awall extending from the rear of the back plate; (5) the wall comprisinga hinged wall integrally molded in the back plate; (6) each of the clipscomprising rear insulation disposed over conductive portions of the clipon an opposite side of the clip from the contact; (7) the rearinsulation being not statically joined to the clip and wherein the rearinsulation insulating cover and the clip slide with respect to eachother as the clip bends outward; and (8) each of the clips furthercomprising a front insulator and a rear insulator, wherein theelectrical connections are sandwiched between the front insulator andrear insulator.

In a fourth exemplary embodiment, a wall-plate system may extend inlongitudinal, lateral, and transverse directions that are orthogonal toone another and may include one or more structures set forth abovecombined with one or more of: (1) a face plate comprising a front, aback, and at least one outlet aperture, wherein the outlet apertureextends through the face plate in the transverse direction; (2) a backplate abutting the back of the face plate; (3) electronic circuitrycomprising a light; (4) at least one spring clip connected to the faceplate and extending rearward away from the back of the face plate in thetransverse direction, the at least one spring clip comprising at leastone first portion of conductive material extending rearward away fromthe back of the face plate in the transverse direction; (5) the leastone spring clip resiliently deflecting between a neutral position and adeflected position located outboard of the neutral position in thelateral direction; (6) at least one insulator positioned outboard of theat least one first portion of conductive material in the lateraldirection; (7) the at least one insulator tracking (e.g., moving backand forth with) the at least one spring clip as the at least one springclip deflects between the neutral position and the deflected position;and (8) at least one second portion of conductive material sandwichedbetween the face plate and the back plate and extending to electricallyconnect the at least one first portion of conductive material to theelectronic circuitry.

Such a wall-plate system may also include one or more structures setforth above combined with one or more of: (1) the face plate furthercomprising a rectangular outer perimeter forming lengthwise andwidthwise extremes of the wall-plate plate in the longitudinal andlateral directions, respectively; (2) the back plate being circumscribedby the rectangular outer perimeter of the face plate; (3) the face platefurther comprising one or more of (a) an edge extending in the lateraldirection to form one extreme of the wall plate system and (b) aplurality of apertures extending in the longitudinal direction throughthe edge; (4) the light comprising a plurality of light sources; (5) atleast one light source of the plurality of light sources beingpositioned proximate each aperture of the plurality of apertures; (6)the plurality of apertures consisting of three apertures; (7) each lightsource of the plurality of light sources comprising an LED; (8) the atleast one insulator being formed of a polymeric material; (9) the atleast one spring clip comprising a first spring clip and a second springclip; (10) the at least one insulator comprising a first insulator and asecond insulator; (11) the first spring clip being positioned outboardof the at least one outlet aperture and inboard of the first insulatorin the lateral direction; (12) the second spring clip being positionedoutboard of the at least one outlet aperture and inboard of the secondinsulator; (13) the first and second spring clips being spaced from oneanother in the lateral direction and located on opposite sides of the atleast one outlet aperture; (14) the first insulator tracking the firstspring clip as the first spring clip deflects between the neutral anddeflected positions corresponding thereto; (15) the second insulatortracking the second spring clip as the second spring clip deflectsbetween the neutral and deflected positions corresponding thereto; (16)the at least one spring clip comprising a base portion and a contactportion and wherein (a) the contact portion extends rearward away fromthe back of the face plate in the transverse direction and (b) the baseportion abuts the back of the face plate; (17) the base portion of theat least one spring clip being sandwiched between the back plate and theface plate; (18) the back of the face plate comprising at least one postextending rearward in the transverse direction; (19) the back platecomprising at least one first aperture extending in the transversedirection therethrough; (20) the base portion of the at least one springclip comprising at least one second aperture extending in the transversedirection therethrough; (21) a post of the at least one post extendingin the transverse direction through the at least one first aperture andthe at least one second aperture to secure the face plate, back plate,and at least one spring clip together; (22) the at least one outletaperture being shaped to admit a face of a duplex outlet therethrough;and (23) the at least one outlet aperture being shaped to admit a faceof a decor outlet therethrough.

In a fifth exemplary embodiment, a wall-plate system may extend inlongitudinal, lateral, and transverse directions that are orthogonal toone another and may include one or more structures set forth abovecombined with one or more of: (1) a face plate comprising a front, aback, and at least one outlet aperture extending therethrough in thetransverse direction; (2) the face plate further comprising an edge andat least one light aperture, wherein the edge extends in the lateraldirection to form one extreme of the wall-plate system and the at leastone light aperture extends in the longitudinal direction through theedge; (3) electronic circuitry comprising at least one light sourcepositioned proximate the at least one light aperture; (4) at least onespring clip connected to the face plate and extending rearward away fromthe back of the face plate in the transverse direction, the at least oneclip comprising at least one first portion of conductive materialextending rearward away from the back of the face plate in thetransverse direction; (5) the least one clip resiliently deflectingbetween a neutral position and a deflected position located outboard theneutral position in the lateral direction; (6) at least one insulatorpositioned outboard of the at least one first portion of conductivematerial in the lateral direction; (7) the at least one insulatortracking (e.g., moving back and forth with) the at least one clip as theat least one clip deflects between the neutral position and thedeflected position; and (8) at least one second portion of conductivematerial extending to electrically connect the at least one firstportion of conductive material to the electronic circuitry.

Such a wall-plate system may also include one or more structures setforth above combined with one or more of: (1) the face plate furthercomprising a rectangular outer perimeter forming lengthwise andwidthwise extremes of the face plate in the longitudinal and lateraldirections, respectively; (2) the at least one spring clip comprising afirst spring clip and a second spring clip; (3) the at least oneinsulator comprising a first insulator and a second insulator; (4) thefirst spring clip being positioned outboard of the at least one outletaperture and inboard of the first insulator in the lateral direction;(5) the second spring clip being positioned outboard of the at least oneoutlet aperture and inboard of the second insulator; and (6) the firstand second spring clips being spaced from one another in the lateraldirection and located on opposite sides of the at least one outletaperture.

In a sixth exemplary embodiment, a wall-plate system may extend inlongitudinal, lateral, and transverse directions that are orthogonal toone another and may include one or more structures set forth abovecombined with one or more of: (1) a face plate comprising a front, aback, at least one outlet aperture extending therethrough in thetransverse direction, and a rectangular outer perimeter, wherein therectangular outer perimeter forms lengthwise and widthwise extremes ofthe wall-plate system in the longitudinal and lateral directions,respectively; (2) the face plate further comprising an edge and at leastone light aperture, wherein the edge extends in the lateral direction toform one lengthwise extreme of the wall-plate system and the at leastone light aperture extends in the longitudinal direction through theedge; (3) a back plate abutting the back of the face plate; (4)electronic circuitry comprising at least one light source positionedproximate the at least one light aperture; (5) first and second springclips, each connecting to the face plate, extending rearward away fromthe back of the face plate in the transverse direction, and comprising aportion of conductive material extending rearward away from the back ofthe face plate in the transverse direction; (6) the first and secondspring clips each resiliently deflecting between a neutral position anda deflected position located outboard the neutral position in thelateral direction; (7) first and second insulators positioned outboardof the portion of conductive material of the first and second springclips, respectively, in the lateral direction; (8) the first and secondinsulators respectively tracking the first and second spring clips asthe first and second spring clips deflect between respective neutral anddeflected positions; and (9) first and second lengths of conductivematerial sandwiched between the face plate and the back plate andextending to respectively electrically connect (a) the portion ofconductive material corresponding to the first spring clip to theelectronic circuitry and (b) the portion of conductive materialcorresponding to the second spring clip to the electronic circuitry.

Such a wall-plate system may also include one or more structures setforth above combined with one or more of: (1) the back of the face platecomprising at least one post extending rearward in the transversedirection; (2) the back plate comprising at least one first apertureextending in the transverse direction therethrough; (3) the base portionof the at least one spring clip comprising at least one second extendingin the transverse direction therethrough; and (4) a post of the at leastone post extending in the transverse direction through the at least onefirst aperture and the at least one second aperture to secure the faceplate, back plate, and at least one spring clip together.

In a seventh exemplary embodiment, a system in accordance with thepresent invention may comprise a cover plate including one or more ofthe following structures: (1) a face plate comprising at least oneoutlet aperture; (2) a back plate abutting a back of the face plate; (3)an electric load between the face plate and the back plate; (4) at leastone prong that extends from the face plate to a free end, the prongconfigured to interface with a terminal on a side of an outletreceptacle body, the prong comprising one or more of (a) an insulatedportion and (b) an electrical contact, wherein the prong resilientlydeflects outward when interfacing with a terminal, and wherein the prongdeflects with a first resistance prior to contacting a wall, and asecond resistance that is greater than the first resistance when theprong contacts the wall; and (5) at least one conductor electricallyconnecting the prong to the electric load.

Such a cover plate may also include one or more structures set forthabove combined with one or more of: (1) the second resistance limitingfurther deformation of the prong; (2) the wall comprising an interiorwall of an electrical receptacle box; (3) the wall being coupleddirectly to and extends from the back plate; (4) the wall being shorterthan the prong; (5) the wall being wider than the prong; (6) contactwith the wall increasing contact pressure between the prong and aterminal; (7) the at least one outlet aperture being shaped to admit aface of a duplex outlet therethrough; (8) the at least one outletaperture being shaped to admit a face of a decor outlet therethrough;(9) the prong being configured to interface with a screw terminal; and(10) the face plate further comprising a subset of posts, and whereinthe prongs and the back plate fit over the posts to retain the prongbetween the face plate and the back plate.

In an eighth exemplary embodiment, a system in accordance with thepresent invention may comprise a cover plate including one or more ofthe following structures: (1) a face plate comprising at least oneoutlet aperture; (2) electronic circuitry; (3) a pair of prongs coupledto the face plate, the pair of prongs comprising a first prong extendingto a first free end and a second prong extending to a second free end,the prongs located on opposite sides of the at least one outletaperture, each prong comprising one or more of (a) a conductive portionand (b) a non-conductive portion comprising a ramp located at the freeend of the prong, wherein the prong resiliently deflects outward wheninterfacing with a terminal on the side of an outlet receptacle body andthe ramp is configured to prevent the conductive portion from contactinga wall of an electrical box; and (4) at least one conductor electricallyconnecting the pair of prongs to electronic circuitry.

Such a cover plate may also include one or more structures set forthabove combined with one or more of: (1) each prong further comprising aportion that extends inward toward the outlet aperture; (2) each prongfurther comprising the ramp is angled away from the outlet aperture; (3)the ramp being further configured to contact an interior wall of theelectrical box; (4) the prongs being configured to interface withopposing screw terminals of an outlet receptacle body; (5) an insulatedcover shielding the conductive portion; (6) the insulating covercomprising an aperture; (7) the conductive portion of each prongcomprising an electrical contact that extends through the aperture ofthe insulated cover; (8) insulating tabs extending from the cover plate;(9) the insulating tabs being shorter than the prongs; (10) the ramp ofeach prong extending over one of the insulating tabs; (11) theinsulating tabs being integrally molded components of the cover plate;(12) the insulating tabs comprising a hinged connection with the coverplate; and (13) the electronic circuitry comprising a light and a lightsensor.

In a ninth exemplary embodiment, a system in accordance with the presentinvention may comprise a cover plate including one or more of thefollowing structures: (1) a face plate comprising at least one outletaperture; (2) at least one prong coupled to the face plate and extendingfrom the faceplate to a free end, the prong configured to electricallycouple to a terminal on the side of an outlet receptacle body, the prongcomprising a conductive portion and a non-conductive portion; and (3) atab located between the prong and an exterior edge of the face plate,the tab shielding an exterior side of the conductive portion of theprong.

Such a cover plate may also include one or more structures set forthabove combined with one or more of: (1) the tab comprising sidewallsthat extend toward the prong; (2) the non-conductive portion of theprong being formed from a resilient polymer; (3) the tab being a freestanding structure; (4) the tab preventing the conductive portion fromphysical contact with conductors located outboard from the prong; (5)the tab preventing the conductive portion from arcing between theconductive portion and conductors located outboard from the prong; (6)the tab being flexible; and (7) the non-conductive portion of the prongcomprising a ramp configured to extend over the tab to prevent the tabfrom touching an electrical receptacle box.

The preceding description has been presented only to illustrate anddescribe examples of the principles described. This description is notintended to be exhaustive or to limit these principles to any preciseform disclosed. Many modifications and variations are possible in lightof the above teaching.

What is claimed is:
 1. An active cover plate comprising: a face plate; an electrical load; at least one clip extending rearward from the faceplate, the clip comprising a contact, a resilient strip supporting the contact, wherein the contact is joined to the resilient strip and passes through the resilient strip, and a rear insulator covering a rear side of the contact; and an electrical connection between the clip and the electrical load.
 2. The active cover plate of claim 1, wherein the resilient strip comprises a base, a bend, and an upright portion.
 3. The active cover plate of claim 1, wherein the rear insulator moves with respect to the main upright portion when the main upright bends.
 4. The active cover plate of claim 2, wherein the rear insulator covers at least a portion of the bend and the upright portion.
 5. The active cover plate of claim 1, further comprising a back plate, wherein the rear insulator comprises an integrally molded feature of the back plate.
 6. The active cover plate of claim 5, wherein the integrally molded feature comprises a wall.
 7. The active cover plate of claim 6, wherein the integrally molded feature comprises a hinged connection to the back plate.
 8. The active cover plate of claim 1, further comprising a back plate, wherein the resilient strip comprises a base sandwiched between the back plate and the face plate.
 9. The active cover plate of claim 8, wherein the face plate comprises posts extending rearward and wherein the back plate and base comprises apertures to accept the posts, the posts securing the base of the resilient strip between the face plate and the back plate.
 10. The active cover plate of claim 9, wherein the posts are compressed to secure the back plate to the face plate.
 11. The active cover plate of claim 1, wherein the contact comprises a major axis and a minor axis, the major axis being at least 20% greater than the minor axis.
 12. The active cover plate of claim 11, wherein the major axis is substantially perpendicular in at least one direction to a rear plane of the face plate.
 13. An active cover plate comprising: a face plate; an electrical load; a clip extending rearward from the face plate to interface with screw terminals of a receptacle body, wherein the clip comprises a contact, a conductor connected to the contact, a front insulator, and a rear insulator, wherein the conductor is disposed between the front insulator and the rear insulator; and an electrical connection between each of the contact and the electrical load.
 14. The active cover plate of claim 13, wherein the rear insulator is joined to the front insulator.
 15. The active cover plate of claim 13, wherein rear insulator covers a rear of the contact.
 16. The active cover plate of claim 13, further comprising a back plate, wherein the rear insulator comprises a molded feature of the back plate.
 17. The active cover plate of claim 13, wherein the conductor is sandwiched between the front insulator and rear insulator.
 18. An active cover plate comprising: a faceplate comprising three spaced apertures along one edge, and posts extending rearward from the faceplate; a load comprising at least three light emitting diodes, wherein light emitted from the three light emitting diodes shine through the three spaced apertures along the one edge of the faceplate, and a light sensor, wherein the light sensor receives ambient light through the aperture on the face of faceplate; a pair of opposing clips extending rearward from the faceplate to interface with opposing screw terminals of an outlet receptacle body, wherein the pair of opposing clips are configured to bend outward as the clips interface with the opposing screw terminals, wherein the each of the clips comprise a contact configured to electrically contact one of the opposing screw terminals; electrical connections connecting each of the contacts and the load; and a back plate, wherein each of the clips fits over posts extending rearward from the faceplate and the back plate fits over posts to sandwich the clips between the faceplate and the back plate, wherein the posts are compressed to secure the prongs and back plate to the face plate.
 19. The active cover plate of claim 18, further comprising a light pipe, wherein the light pipe is configured to fit into the three spaced apertures and direct light from the at least three light emitting diodes out through the three space apertures.
 20. The active cover plate of claim 18, wherein each clip comprises: a main ramp configured to guide the spring clips around the outlet receptacle body, wherein the main ramps are configured to contact a wall as the clips bend outward and interface with the opposing screw terminals; and wherein contact with the wall by the main ramp increases contact pressure between the contact and the screw terminal.
 21. The active cover plate of claim 20, wherein the wall comprises an interior wall of an outlet receptacle box.
 22. The active cover plate of claim 20, wherein the wall comprises a wall extending from the rear of the back plate.
 23. The active cover plate of claim 22, wherein the wall comprises a hinged wall integrally molded in the back plate.
 24. The active cover plate of claim 18, wherein each of the clips comprises rear insulation disposed over conductive portions of the clip on an opposite side of the clip from the contact.
 25. The active cover plate of claim 24, wherein the rear insulation is not statically joined to the clip and wherein the rear insulation insulating cover and the clip slide with respect to each other as the clip bends outward.
 26. The active cover plate of claim 18, wherein each of the clips further comprises a front insulator and a rear insulator, wherein the electrical connections are sandwiched between the front insulator and rear insulator. 